TW201429577A - Press forming method - Google Patents
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- TW201429577A TW201429577A TW102102006A TW102102006A TW201429577A TW 201429577 A TW201429577 A TW 201429577A TW 102102006 A TW102102006 A TW 102102006A TW 102102006 A TW102102006 A TW 102102006A TW 201429577 A TW201429577 A TW 201429577A
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本發明係有關於一種可將高強度鋼板成形為於長向上設有彎曲部之最終成形品之壓製成形方法。尤其，本發明係有關於一種可抑制殘餘應力所致最終成形品之翹曲及扭曲之壓製成形方法。 The present invention relates to a press forming method capable of forming a high-strength steel sheet into a final molded article having a bent portion in a long direction. In particular, the present invention relates to a press forming method capable of suppressing warpage and distortion of a final molded article due to residual stress.
近年，就汽車之燃料費上揚、碰撞安全性提昇之觀點而考量，已特別就骨架結構使用拉伸強度較高之高強度鋼板及鋁合金。拉伸強度較高之材質無須增加材質之厚度即可提昇碰撞性能，故有助於輕量化。 In recent years, in view of the increase in the fuel cost of automobiles and the improvement of the safety of collisions, high-strength steel sheets and aluminum alloys having high tensile strength have been used particularly for the skeleton structure. A material with a high tensile strength can increase the collision performance without increasing the thickness of the material, so it contributes to weight reduction.
然而，材料之高強度化則使壓製成形之殘餘應力所致最終成形品之翹曲及扭曲增加，如何確保最終成形品之形狀精度即成問題。 However, the high strength of the material increases the warpage and distortion of the final molded article due to the residual stress of press forming, and how to ensure the shape accuracy of the final molded article becomes a problem.
無法確保最終成形品之形狀精度時，將於對車輛進行組裝時在與對象零件之間產生間隙，間隙量較大時則將導致組裝瑕疵。因此，須嚴格要求最終成形品之形狀精度。又，最終成形品之彎曲部之曲率較小之零件，即彎曲部之最小曲率半徑為50~2000mm時，將特別要求高度之形 狀精度。彎曲部之形狀係圓弧或連續地改變曲率之曲面。最終成形品中存在複數個上述彎曲部時，伴隨最終成形品之面內應力而發生之最終成形品長向上之翹曲及扭曲較為嚴重。因此，更難以確保最終成形品之精度。 When the shape accuracy of the final molded product cannot be ensured, a gap is formed between the target component and the target component when the vehicle is assembled, and when the amount of the gap is large, assembly defects are caused. Therefore, the shape accuracy of the final molded article must be strictly required. Further, when the curvature of the curved portion of the final molded product is small, that is, the minimum radius of curvature of the curved portion is 50 to 2000 mm, the height is particularly required. Accuracy. The shape of the curved portion is an arc or a curved surface that continuously changes the curvature. When a plurality of the above-mentioned bent portions are present in the final molded article, warpage and distortion of the final molded article length accompanying the in-plane stress of the final molded article are severe. Therefore, it is more difficult to ensure the precision of the final molded article.
習知之一般形狀精度瑕疵對策係依據最終成形品之試作及過往經驗，而採用預測回彈發生量並將模具形狀構成與最終成形品之形狀不同之形狀以符合預定尺寸之方法。而，近年，則在最終成形品之試作前基於最終形狀而進行採用有限元素法之回彈等之壓製成形分析而製作模具，以減少試作時模具修正之次數。 The conventional shape accuracy 习 countermeasure is based on the test of the final molded article and the past experience, and adopts a method of predicting the amount of rebound occurrence and forming a shape different from the shape of the final molded article to conform to a predetermined size. In recent years, a mold is produced by press forming analysis using a finite element method or the like based on the final shape before the final molded product is tested, so that the number of times of mold correction at the time of trial production is reduced.
然而，基於嘗試錯誤之模具設計在構思可充分減少翹曲及扭曲之模具形狀並確立成形條件之前極為耗時之問題。且，由於藉嘗試錯誤進行模具設計，故將增加模具修正費用而有妨礙最終成形品之低成本化之問題。 However, the mold design based on the trial error is extremely time consuming in the concept of sufficiently reducing the shape of the warp and twisted mold and establishing the forming conditions. Further, since the mold design is attempted by mistake, the mold correction cost is increased and the problem of lowering the cost of the final molded product is hindered.
最終成形品之形狀精度提昇對策已揭露有一種對最終成形品加設焊道，而抑制最終成形品之翹曲及扭曲之技術(專利文獻1)。又，亦已揭露一種於鑄模與胚料托座之保持面間局部推壓胚料而於胚料上成形焊道，以增加縱壁部之張力而確保最終成形品之形狀精度之技術(專利文獻2)。 A measure for improving the shape accuracy of the final molded article has been disclosed in which a weld bead is added to the final molded article to suppress warpage and distortion of the final molded article (Patent Document 1). Moreover, a technique for locally pressing a billet between a holding surface of a mold and a billet holder to form a bead on the billet to increase the tension of the vertical wall portion and ensuring the shape accuracy of the final molded article has been disclosed (patent Literature 2).
專利文獻1及專利文獻2所揭露之技術係對最終成形品加設焊道而改良產品形狀以抑制回彈。因此，可應用之最終成形品之形狀較為受限，而有無法加以泛用之問題。 The techniques disclosed in Patent Document 1 and Patent Document 2 add a weld bead to the final molded article to improve the shape of the product to suppress rebound. Therefore, the shape of the final molded article that can be applied is limited, and there is a problem that it cannot be used in general.
專利文獻3則揭露了可提昇包含頂板部、縱壁部及凸緣部之具有帽型截面形狀之壓製成形品之形狀精度之壓製成形方法。專利文獻3所揭露之壓製成形方法係將金屬板壓製成形為於縱壁部與凸緣部之間具有錐部之成形半成品，再就上述半成品之錐部與凸緣部再度進行壓製成形而製得最終成形品。 Patent Document 3 discloses a press forming method capable of improving the shape accuracy of a press-formed product having a hat-shaped cross-sectional shape including a top plate portion, a vertical wall portion, and a flange portion. The press forming method disclosed in Patent Document 3 press-forms a metal plate into a molded semi-finished product having a tapered portion between the vertical wall portion and the flange portion, and further press-forms the tapered portion and the flange portion of the semi-finished product. The final molded product is obtained.
然而，專利文獻3所揭露之壓製成形方法乃用於提高最終成形品之縱壁部與凸緣部之角度精度，而改善凸緣部之平坦度者，並非用於抑制最終成形品整體之翹曲及扭曲者。 However, the press forming method disclosed in Patent Document 3 is for improving the angular accuracy of the vertical wall portion and the flange portion of the final molded article, and improving the flatness of the flange portion is not intended to suppress the warpage of the final molded article as a whole. Qu and twisted.
專利文獻4則揭露了一種可提昇包含頂板部及縱壁部，並設有彎曲部之最終成形品之形狀精度之壓製成形方法。專利文獻4所揭露之壓製成形方法係將金屬板彎曲加工成頂板部與縱壁部之彎曲角度之彎曲量大於最終成形品之半成品後，再進行回復最終成形品之彎曲角度之彎曲加工。 Patent Document 4 discloses a press forming method capable of improving the shape accuracy of a final molded article including a top plate portion and a vertical wall portion and having a bent portion. The press forming method disclosed in Patent Document 4 bends a metal plate into a bending process in which the bending angle of the top plate portion and the vertical wall portion is larger than the semi-finished product of the final molded product, and then the bending process of returning the bending angle of the final molded article is performed.
然而，專利文獻4之壓製成形方法在金屬板為軟鋼板等拉伸強度不高之金屬板時，雖可抑制最終成形品之翹曲及扭曲，但用於高強度鋼板等拉伸強度較高之金屬板時，則無法抑制最終成形品之翹曲及扭曲。且，當最終成形品包含凸緣部，而截面形狀為帽型時，則易於彎曲部內側之凸緣部殘留拉伸應力，故有最終成形品之翹曲及扭曲更為嚴重之問題。 However, in the press forming method of Patent Document 4, when the metal plate is a metal plate having a low tensile strength such as a soft steel plate, warpage and distortion of the final molded article can be suppressed, but the tensile strength is high for a high-strength steel sheet or the like. In the case of a metal plate, warpage and distortion of the final molded article cannot be suppressed. Further, when the final molded article includes the flange portion and the cross-sectional shape is a hat shape, the tensile stress is likely to remain in the flange portion inside the curved portion, and thus the warpage and distortion of the final molded article are more serious.
【專利文獻1】日本專利特開2004-25273號公報 [Patent Document 1] Japanese Patent Laid-Open Publication No. 2004-25273
【專利文獻2】日本專利特開平11-290951號公報 [Patent Document 2] Japanese Patent Laid-Open No. Hei 11-290951
【專利文獻3】日本專利特開2006-289480號公報 [Patent Document 3] Japanese Patent Laid-Open Publication No. 2006-289480
【專利文獻4】日本專利特開2004-195535號公報 [Patent Document 4] Japanese Patent Laid-Open Publication No. 2004-195535
本發明之目的在提供一種在壓製成形高強度鋼板時，無須對最終成形品設置焊道等，即可減少殘留於彎曲部內側之拉伸應力所導致最終成形品之翹曲及扭曲之壓製成形方法。 SUMMARY OF THE INVENTION An object of the present invention is to provide a press forming method for reducing warpage and distortion of a final molded article by reducing the tensile stress remaining inside the bent portion without forming a weld bead or the like on the final molded article. method.
本發明人等人發現了將高強度鋼板壓製成形為包含頂板部、縱壁部及凸緣部且於長向上設有至少1個最小曲率半徑為50~2000mm之彎曲部之最終成形品時，為減少最終成形品之翹曲及扭曲，需要以下之方法。 The present inventors have found that when a high-strength steel sheet is press-formed into a final molded article including a top plate portion, a vertical wall portion, and a flange portion and having at least one bent portion having a minimum radius of curvature of 50 to 2000 mm in the longitudinal direction, In order to reduce warpage and distortion of the final molded article, the following method is required.
本發明將壓製成形分為以下二步驟：1)第1成形步驟，在包含連結縱壁部與凸緣部之交集部及彎曲部之曲率中心之水平線並與高強度鋼板垂直之平面內，於交集部進行凸緣部之彎曲加工至凸緣部對前述水平線之角度為α1為止；2)第2成形步驟，於交集部進行前述第1成形步驟後之凸緣部之追加彎曲加工至凸緣部對前述水平線之角度為α2為止。 In the present invention, the press forming is divided into the following two steps: 1) the first forming step includes a horizontal line connecting the intersection of the vertical wall portion and the flange portion and the center of curvature of the curved portion and perpendicular to the high-strength steel sheet. the intersection portion of the bending portion to the flange portion of the horizontal flange of the angle [alpha] of up to 1; additionally bent to the rear of the flange portion 2 of) the second molding step, a step of molding the first convex portion to the intersection The angle of the edge to the aforementioned horizontal line is α 2 .
本發明人等人已發現此時若α1-α2所代表之追加彎曲角β在預定範圍內，則可減少最終成形品之翹曲及扭曲。且，本發明人等人並發現即便使用容易發生回彈之拉伸強度為440~4600MPa之高強度鋼板，若使追加彎曲角β在預定範圍內，亦可使翹曲量及扭曲量與使用拉伸強度未滿440MPa之鋼板時為相同之程度。 The present inventors have found that at this time, if the additional bending angle β represented by α 1 - α 2 is within a predetermined range, the warpage and distortion of the final molded article can be reduced. Further, the inventors of the present invention have found that even if a high-strength steel sheet having a tensile strength of 440 to 4600 MPa which is liable to rebound is used, if the additional bending angle β is within a predetermined range, the amount of warpage and the amount of warpage and the amount of twist can be used. The steel sheet having a tensile strength of less than 440 MPa is the same degree.
本發明即基於上述發現而完成，其要旨如下。 The present invention has been completed based on the above findings, and the gist thereof is as follows.
(1)本發明係一種壓製成形方法，係用於壓製成形包含頂板部、縱壁部及凸緣部，並於長向上設有至少1彎曲部之最終成形品者，包含以下步驟：第1成形步驟，使用拉伸強度為440~1600MPa之高強度鋼板而形成頂板部、縱壁部、彎曲部及凸緣部時，在包含連結縱壁部與凸緣部之交集部與彎曲部之曲率中心之水平線並與前述高強度鋼板垂直之平面內，於交集部進行凸緣部之彎曲加工至凸緣部對前述水平線之角度為α1為止；及，第2成形步驟，於前述平面內，於交集部進行前述第1成形步驟後之凸緣部之追加彎曲加工至凸緣部對前述水平線之角度為α2為止；於前述平面內，將彎曲部之曲率半徑設為R0(mm)，並將凸緣部之長度設為b(mm)，代表應變之容許值之數值設為εcr，前述高強度鋼板之楊氏模數及拉伸強度則設為E(MPa)及σT(MPa)，α1及α2係以前述水平線為起點，並以凸緣部朝遠離頂板部之方向旋轉之方向為正向，當α1>0，α2≧0，α1-α2>0，R0為50~2000mm及εcr為0~0.023時，作為α1-α2之追加彎曲角β，在【數1】中，係在下述範圍內，且，在【數 2】中，係在下述範圍內。 (1) The present invention is a press forming method for press forming a final molded article including a top plate portion, a vertical wall portion, and a flange portion and having at least one bent portion in the long direction, comprising the following steps: In the forming step, when the top plate portion, the vertical wall portion, the curved portion, and the flange portion are formed using a high-strength steel sheet having a tensile strength of 440 to 1600 MPa, the curvature of the intersection portion and the curved portion connecting the vertical wall portion and the flange portion is included and the center of the horizontal line, with a plane perpendicular to the intersection of high-strength steel sheet in the bent portion of the flange portion to the flange portion of the horizontal angle of up to α 1; and, a second step of forming, in the plane, The flange portion of the intersection portion is subjected to the additional bending process after the first forming step until the angle of the flange portion with respect to the horizontal line is α 2 ; and the radius of curvature of the curved portion is R 0 (mm) in the plane. And the length of the flange portion is set to b (mm), the value representing the allowable value of the strain is εcr, and the Young's modulus and tensile strength of the high-strength steel sheet are set to E (MPa) and σ T ( MPa), α 1 and α 2 are based on the aforementioned horizontal line. And the direction in which the flange portion rotates away from the top plate portion is forward, when α 1 >0, α 2 ≧0, α 1 -α 2 >0, R 0 is 50-2000 mm, and εcr is 0-0.023 The additional bending angle β of α 1 -α 2 is within the following range in [Number 1], and is in the following range in [Number 2].
(2)如上述(1)所揭露之壓製成形方法，其中前述彎曲部係圓弧或連續地改變曲率之曲線。 (2) The press forming method as disclosed in (1) above, wherein the curved portion is a circular arc or a curve in which the curvature is continuously changed.
(3)如上述(1)或(2)所揭露之壓製成形方法，其中前述第1成形步驟及第2成形步驟之至少任一中，將對向之模具之一者分割為襯墊與局部成形模具，並藉襯墊與前述對向之模具之另一者壓緊鋼板，而藉局部成形模具與前述對向之模具之另一者使鋼板塑性變形。 (3) The press-molding method according to (1) or (2) above, wherein at least one of the first forming step and the second forming step is divided into a pad and a part The mold is formed, and the steel sheet is pressed against the other of the opposing molds by the liner, and the steel sheet is plastically deformed by the other of the partial forming mold and the opposing mold.
依據本發明，即便使用高強度鋼板，亦無須對最 終成形品設置焊道等，即可抑制包含頂板部、縱壁部及凸緣部且於長向上設有至少1個曲率半徑為50~2000mm之彎曲部之最終成形品之翹曲及扭曲。 According to the present invention, even if a high-strength steel plate is used, it is not necessary to When a weld bead or the like is provided in the final molded article, warpage and distortion of the final molded article including the top plate portion, the vertical wall portion, and the flange portion and having at least one curved portion having a radius of curvature of 50 to 2000 mm in the longitudinal direction can be suppressed. .
1‧‧‧最終成形品 1‧‧‧ final molded product
2、2a‧‧‧頂板部 2, 2a‧‧‧ top board
3a、3b、3-1a、3-2a‧‧‧縱壁部 3a, 3b, 3-1a, 3-2a‧‧ ‧ vertical wall
4a、4b、4-1a、4-2a‧‧‧凸緣部 4a, 4b, 4-1a, 4-2a‧‧‧Flange
5a、5b‧‧‧交集部 5a, 5b‧‧‧Intersection Department
10、10-1、10-2‧‧‧彎曲部 10, 10-1, 10-2‧‧‧ bending
50‧‧‧第1模具 50‧‧‧1st mould
52、62‧‧‧頂板部成形面 52, 62‧‧‧ top plate forming surface
53a、63a‧‧‧內側縱壁部成形面 53a, 63a‧‧‧ inside vertical wall forming surface
53b、63b‧‧‧外側縱壁部成形面 53b, 63b‧‧‧ outside longitudinal wall forming surface
54a、64a‧‧‧內側凸緣部成形面 54a, 64a‧‧‧Inside flange forming surface
54b、64b‧‧‧外側凸緣部成形面 54b, 64b‧‧‧Outer flange forming surface
55a、55b‧‧‧襯墊 55a, 55b‧‧‧ pads
56a、56b‧‧‧局部成形模具 56a, 56b‧‧‧ Partial forming mould
60‧‧‧第2模具 60‧‧‧2nd mould
80‧‧‧壓製機 80‧‧‧ Press
81‧‧‧小型油壓汽缸 81‧‧‧Small hydraulic cylinder
90‧‧‧鋼板 90‧‧‧ steel plate
92‧‧‧最終成形品中構成頂板部之部位 92‧‧‧The part of the final molded product that constitutes the top plate
H‧‧‧水平線 H‧‧‧ horizontal line
L1‧‧‧線段 L1‧‧‧ line segment
L2、L3‧‧‧位置 L2, L3‧‧‧ position
Lo‧‧‧曲率中心軸 Lo‧‧‧ Curvature Center Axis
Lo’‧‧‧軸 Lo’‧‧‧ axis
O‧‧‧曲率中心 O‧‧‧ Curvature Center
P、Q、S、T‧‧‧點 P, Q, S, T‧‧ points
P0、Q0、S0、T0‧‧‧最終成形品之位置測定點 P 0 , Q 0 , S 0 , T 0 ‧‧‧ Position measurement point of the final molded product
r‧‧‧位置 R‧‧‧ position
S1‧‧‧微小平面 S1‧‧‧micro plane
T0T‧‧‧線段 T 0 T‧‧‧ line segment
W‧‧‧頂板部之寬度 W‧‧‧The width of the top plate
α1、α2‧‧‧角度 α 1 , α 2 ‧‧‧ angle
β‧‧‧追加彎曲角 β‧‧‧Additional bending angle
圖1(a)、1(b)係顯示設有1個彎曲部之最終成形品之一例者。 Fig. 1 (a) and Fig. 1 (b) show an example of a final molded article provided with one bent portion.
圖2係顯示對高強度鋼板施加拉伸及壓縮負載後之高強度鋼板所承載之應力變化者。 Fig. 2 is a graph showing changes in stress carried by a high-strength steel sheet after applying a tensile and compressive load to a high-strength steel sheet.
圖3係顯示設有2個彎曲部之最終成形品者。 Fig. 3 shows a final molded article provided with two bent portions.
圖4係顯示第1成形步驟中使用之模具之用於成形彎曲部之部分之截面構造之概況之模式圖。 Fig. 4 is a schematic view showing an outline of a cross-sectional structure of a portion for forming a bent portion of a mold used in the first forming step.
圖5係顯示成形寬度W為15~30mm之最終成形品時，第1成形步驟中使用之模具之用於成形彎曲部之部分之截面構造之概況之模式圖。 Fig. 5 is a schematic view showing an outline of a cross-sectional structure of a portion of a mold used in the first molding step for forming a bent portion when the final molded article having a molding width W of 15 to 30 mm is formed.
圖6係顯示成形寬度W為15~30mm之最終成形品時，第2成形步驟中使用之模具之用於成形彎曲部之部分之截面構造之概況之模式圖。 Fig. 6 is a schematic view showing an outline of a cross-sectional structure of a portion of a mold used in the second forming step for forming a bent portion when the final molded article having a molding width W of 15 to 30 mm is formed.
圖7係顯示包含彎曲部之曲率半徑在700~1200mm之範圍內連續變化之部位與直線部之朝長向俯視方向和緩彎曲之最終成形品之形狀者。 Fig. 7 is a view showing a shape of a final molded article including a portion in which the curvature radius of the curved portion continuously changes in the range of 700 to 1200 mm and a straight portion in a plan view direction and a gentle bending.
圖8係顯示包含曲率半徑為1000mm與700mm之彎曲部與直線部，進而組合有曲率半徑在1200~2000mm之範圍內連續變化之形狀而朝長向俯視方向和緩彎曲之最終成形品者。 Fig. 8 is a view showing a final molded article including a curved portion and a straight portion having a curvature radius of 1000 mm and 700 mm, and a shape in which a radius of curvature is continuously changed in the range of 1200 to 2000 mm and which is bent in a long-term direction and gently curved.
圖9係顯示包含曲率半徑為1000mm與700mm之彎曲部 與直線部，進而組合有曲率半徑在1200~2000mm之範圍內連續變化之形狀而朝長向俯視方向和緩彎曲之最終成形品者。另，進行追加彎曲之範圍係內側凸緣之局部。 Figure 9 shows a bend containing a radius of curvature of 1000 mm and 700 mm. Further, in combination with the straight portion, a final molded article having a shape in which the radius of curvature is continuously changed in the range of 1200 to 2000 mm and which is gradually curved in a plan view in a long direction is combined. In addition, the range in which the additional bending is performed is a part of the inner flange.
圖10係顯示包含曲率半徑為1000mm之彎曲部與直線部，並於側面視方向上包含曲率半徑為3000mm之彎曲部與直線部而朝長向俯視方向和緩彎曲之最終成形品者。 Fig. 10 shows a final molded article including a curved portion and a straight portion having a curvature radius of 1000 mm and a curved portion and a straight portion having a radius of curvature of 3000 mm in the side view direction and gently curved in a plan view in a long direction.
圖11係顯示設有1個彎曲部之最終成形品之一例者。 Fig. 11 shows an example of a final molded article provided with one bent portion.
圖12係顯示彎曲部10之曲率半徑R0(mm)與對最終成形品施加之ε1對最終成形品之翹曲、扭曲及皺褶所造成之影響者。 Fig. 12 shows the influence of the radius of curvature R 0 (mm) of the curved portion 10 and the ε 1 applied to the final molded article on the warpage, distortion and wrinkles of the final molded article.
圖13(a)、13(b)係說明α1及α2之正負之方向者。 13(a) and 13(b) show the directions of positive and negative of α 1 and α 2 .
圖14係顯示α2+β超過90°時之圖1(a)中之I-I線之最終成形品之截面者。 Fig. 14 is a view showing a section of the final molded article of the line II in Fig. 1(a) when α 2 + β exceeds 90°.
圖1係顯示包含頂板部、縱壁部及凸緣部並於長向上設有1個曲率半徑為50~2000mm之彎曲部之最終成形品之一例者。圖1(a)為立體圖，圖1(b)為沿行圖1(a)所示之I-I線之截面圖。圖1(a)中，標號1代表最終成形品。 Fig. 1 shows an example of a final molded article including a top plate portion, a vertical wall portion, and a flange portion and having a curved portion having a radius of curvature of 50 to 2000 mm in the longitudinal direction. Fig. 1(a) is a perspective view, and Fig. 1(b) is a cross-sectional view taken along line I-I shown in Fig. 1(a). In Fig. 1(a), reference numeral 1 denotes a final molded article.
最終成形品1包含頂板部2、縱壁部3a、3b、凸緣部4a、4b。縱壁部3a及凸緣部4a係彎曲部10之內側，縱壁部3b、凸緣部4b係彎曲部10之外側。縱壁部3a與凸緣部4a交集於交集部5a。縱壁部3b與凸緣部4b則交集於交集部5b。 The final molded product 1 includes a top plate portion 2, vertical wall portions 3a and 3b, and flange portions 4a and 4b. The vertical wall portion 3a and the flange portion 4a are inside the curved portion 10, and the vertical wall portion 3b and the flange portion 4b are outside the curved portion 10. The vertical wall portion 3a and the flange portion 4a overlap each other in the intersection portion 5a. The vertical wall portion 3b and the flange portion 4b intersect at the intersection portion 5b.
圖1(b)係顯示圖1(a)中之I-I線之截面形狀者。實 線所代表之截面係第2成形步驟後即最終成形品1之截面。第2成形步驟後之凸緣部4a之位置為L3。且，虛線所代表之截面係第1成形步驟後之凸緣部4a之截面。第1成形步驟後之凸緣部4a之位置為L2。 Fig. 1(b) shows the cross-sectional shape of the line I-I in Fig. 1(a). real The cross section represented by the line is the cross section of the final molded product 1 after the second forming step. The position of the flange portion 4a after the second forming step is L3. Further, the cross section represented by the broken line is the cross section of the flange portion 4a after the first forming step. The position of the flange portion 4a after the first forming step is L2.
關於縱壁部3a與凸緣部4a之交集部5a上之彎曲部之1位置r，則定義該彎曲部之位置r所對應之曲率中心為O、連接該曲率中心O與位置r之線段L1則定義成如圖1(b)所示。 Regarding the position r of the curved portion on the intersection portion 5a of the vertical wall portion 3a and the flange portion 4a, the curvature center corresponding to the position r of the curved portion is defined as O, and the line segment L1 connecting the curvature center O and the position r is defined. It is defined as shown in Figure 1(b).
對曲率中心O可考量彎曲部之位置r之曲率中心軸Lo周圍之微小範圍△θ。就通過線段L1而包含微小範圍△θ之微小平面S1加以定義。微小平面S1則構成包含線段L1及與曲率中心軸Lo垂直之軸Lo’之水平面之一部分。另，該水平面係作為基準面並為求方便而設為水平者。以下之說明將藉圖1(a)中之I-I線之截面即圖1(b)所示之截面而進行說明。圖1(b)所示之截面係包含連結縱壁部3a與凸緣部4a之交集部5a及彎曲部10之曲率中心O之水平線H並與作為材料之鋼板垂直之平面。 For the center of curvature O, a small range Δθ around the curvature center axis Lo of the position r of the curved portion can be considered. A minute plane S1 including a small range Δθ by the line segment L1 is defined. The minute plane S1 constitutes a part of the horizontal plane including the line segment L1 and the axis Lo' perpendicular to the curvature center axis Lo. In addition, the horizontal plane is used as a reference surface and is set to be horizontal for convenience. The following description will be made by the cross section of the line I-I in Fig. 1(a), that is, the cross section shown in Fig. 1(b). The cross section shown in Fig. 1(b) includes a plane perpendicular to the horizontal line H connecting the intersection portion 5a of the vertical wall portion 3a and the flange portion 4a and the center of curvature O of the curved portion 10, and perpendicular to the steel sheet as the material.
最終成形品1之成形步驟則說明如下。首先，就作為材料之鋼板於交集部5a進行彎曲加工至凸緣部4a對水平線H形成角度α1。上述彎曲加工即第1成形步驟。其次，於交集部5a進行第1成形步驟後之凸緣部4a之追加彎曲加工至凸緣部對水平線H形成角度α2。上述追加彎曲加工即第2成形步驟。即，第1成形步驟中，將作為材料之鋼板成形為半成品，並於第2成形步驟中進而就上述半成品之凸緣部 4a進行追加彎曲加工而製得最終成形品1。 The forming step of the final molded article 1 will be described below. First, the steel sheet as a material is bent at the intersection portion 5a to the flange portion 4a to form an angle α 1 with respect to the horizontal line H. The above bending process is the first forming step. Next, the flange portion 4a after the first forming step is subjected to additional bending processing in the intersection portion 5a until the flange portion forms an angle α 2 with respect to the horizontal line H. The second bending step is the additional bending process. In other words, in the first molding step, the steel sheet as the material is formed into a semi-finished product, and the final molded product 1 is obtained by additionally bending the flange portion 4a of the semi-finished product in the second molding step.
第1成形步驟結束時，拉伸應力將殘留於彎曲部10之內側之縱壁部3a及凸緣部4a。上述拉伸殘餘應力乃回彈之原因。因此，接續第1成形步驟而進行追加彎曲加工(第2成形步驟)，即可使縱壁部3a與凸緣部4a之交集部5a發生壓縮塑性變形。其結果，則可減少第1成形步驟結束時之拉伸殘餘應力，而可抑制最終成形品1之翹曲及扭曲。 When the first molding step is completed, the tensile stress remains in the vertical wall portion 3a and the flange portion 4a inside the curved portion 10. The above tensile residual stress is the cause of the rebound. Therefore, by performing the additional bending process (second molding step) following the first molding step, the intersection portion 5a of the vertical wall portion 3a and the flange portion 4a can be compression-plastically deformed. As a result, the tensile residual stress at the end of the first molding step can be reduced, and the warpage and distortion of the final molded article 1 can be suppressed.
圖1(b)所示之截面上，則於上述截面上藉縱壁部3a與凸緣部4a之交集部5a而定義彎曲部10之曲率半徑R0(mm)。在此，第1成形步驟結束時之凸緣部4a先端之曲率半徑設為R1(mm)。第2成形步驟結束時，即最終成形品之凸緣部4a先端之曲率半徑則設為R2(mm)。且，凸緣部4a之長度則設為b。此時，即如下式所示。 In the cross section shown in Fig. 1(b), the curvature radius R 0 (mm) of the curved portion 10 is defined by the intersection portion 5a of the vertical wall portion 3a and the flange portion 4a in the above cross section. Here, the radius of curvature of the tip end of the flange portion 4a at the end of the first molding step is R 1 (mm). When the second molding step is completed, the radius of curvature of the tip end of the flange portion 4a of the final molded product is R 2 (mm). Further, the length of the flange portion 4a is set to b. At this time, it is as shown in the following equation.
R1=R0-bcosα1 R2=R0-bcosα2 R 1 =R 0 -bcosα 1 R 2 =R 0 -bcosα 2
另，R0、R1、R2係微小範圍△θ之曲率半徑。因此，彎曲部10可為曲率連續變化之自由曲面。 Further, R 0 , R 1 , and R 2 are curvature radii of a small range Δθ. Therefore, the curved portion 10 can be a free curved surface whose curvature continuously changes.
此時，凸緣部4a之先端部所發生之應變ε1可以下式代表之。 At this time, the strain ε 1 generated at the tip end portion of the flange portion 4a can be represented by the following formula.
ε1=(R1-R2)/R1=b(cosα2-cosα1)/(R0-bcosα1) ε 1 =(R 1 -R 2 )/R 1 =b(cosα 2 -cosα 1 )/(R 0 -bcosα 1 )
依據上述應變ε1，第1成形步驟中成形之縱壁部3a與凸緣部4a所形成之角度α1則為：α1=cos-1((bcosα2-ε1R0)/b(1-ε1)) According to the strain ε 1 , the angle α 1 formed by the vertical wall portion 3a and the flange portion 4a formed in the first forming step is α 1 =cos -1 ((bcosα 2 - ε 1 R 0 )/b( 1-ε 1 ))
因此，可將α1改為α2之追加彎曲角β則為： β=α1-α2=cos-1((bcosα2-ε1R0)/(b(1-ε1))-α2．．．(A) Therefore, the additional bending angle β at which α1 can be changed to α2 is: β = α 1 - α 2 = cos -1 ((bcosα 2 - ε 1 R 0 ) / (b(1 - ε 1 )) - α 2 ...(A)
在此，凸緣部4a之先端部所發生之應變ε1若在拉伸強度未滿440MPa之鋼板(諸如軟鋼板)等上，則為ε1=σT/E(但σT係鋼板之拉伸強度(MPa)，E係鋼板之楊氏模數(MPa))。 Here, the strain ε 1 generated at the tip end portion of the flange portion 4a is ε 1 = σ T /E if it is on a steel plate (such as a soft steel plate) having a tensile strength of less than 440 MPa (but the σ T- based steel plate) Tensile strength (MPa), Young's modulus (MPa) of E-based steel sheets.
然而，作為壓製成形之材料而使用之鋼板之拉伸強度為440~1600MPa時，即，為高強度鋼板(高張力鋼板)時，將發生ε1小於σT/E之現象。 However, when the tensile strength of the steel sheet used as the material for press forming is 440 to 1600 MPa, that is, when it is a high-strength steel sheet (high-tensile steel sheet), ε 1 is smaller than σ T /E.
以下說明上述現象。第2圖係對拉伸強度為440~1600MPa之高強度鋼板施加拉伸負載至即將破裂之程度，然後，顯示施加壓縮負載後之高強度鋼板所承載之應力變化者。 The above phenomenon will be described below. Fig. 2 is a graph showing the tensile load applied to the high-strength steel sheet having a tensile strength of 440 to 1600 MPa to the extent of rupture, and then the change in the stress carried by the high-strength steel sheet after the application of the compressive load is shown.
拉伸強度為440~1600MPa之高強度鋼板將因鮑辛格效應而於應力反轉時，發生高強度鋼板之再降伏所需之應力△σ較通常之降伏應力減少之早期降伏現象。故而，ε1亦將減少。 When a high-strength steel plate with a tensile strength of 440 to 1600 MPa is subjected to stress reversal due to the Bowinger effect, the stress Δσ required for the re-elevation of the high-strength steel sheet is lower than that of the normal relief stress. Therefore, ε 1 will also decrease.
在此，ε1乃為減少作為回彈之成因之殘留於彎曲部10之內側之拉伸應力而施加之壓縮應變。壓縮應變之下限可為ε1=0.5σT/E。另，壓縮應變之上限可為ε1=0.5σT/E+εcr。在此，εcr係不致使最終成形品1之凸緣部4a發生皺褶之應變之容許值。εcr之範圍已藉實驗而求出為0~0.023。即，最終成形品1中，ε1在0.5σT/E~(0.5σT/E)+εcr之範圍內時，凸緣部4a將不發生皺褶。第1成形步驟中製得半成品時亦同。 Here, ε 1 is a compressive strain applied to reduce the tensile stress remaining on the inner side of the curved portion 10 as a cause of the rebound. The lower limit of the compressive strain may be ε 1 = 0.5 σ T /E. In addition, the upper limit of the compressive strain may be ε 1 = 0.5 σ T / E + εcr. Here, εcr is an allowable value of strain which does not cause wrinkles of the flange portion 4a of the final molded product 1. The range of εcr has been determined by experiments to be 0~0.023. That is, in the final molded product 1, when ε 1 is in the range of 0.5 σ T /E~(0.5 σ T /E) + εcr, the flange portion 4a does not wrinkle. The same applies to the preparation of the semi-finished product in the first forming step.
若將ε1之範圍基於以上(A)式而轉換為追加彎曲角β之範圍，則如【數3】所示。 When the range of ε 1 is converted into the range of the additional bending angle β based on the above formula (A), it is as shown in [3].
圖12係顯示基於上述之不等式而作成之彎曲部10之曲率半徑R0(mm)與壓縮應變ε1對最終成形品之翹曲、扭曲及皺褶所造成之影響者。圖12中，曲線1係作為材料而使用之鋼板之拉伸強度σT為390、490、590、710、980及1200MPa時分別顯示【數4】之曲線。 Fig. 12 is a view showing the influence of the curvature radius R 0 (mm) of the curved portion 10 and the compressive strain ε 1 on the warpage, distortion, and wrinkles of the final molded article based on the above inequality. In Fig. 12, the curve 1 shows a curve of [4] when the tensile strength σ T of the steel sheet used as a material is 390, 490, 590, 710, 980, and 1200 MPa, respectively.
圖12中，ε1之範圍與曲線1之上下可區分為領域A~領域D。領域A及B係εcr為0~0.023之範圍之領域，即，係ε1為對0.5σT/E加算應變之容許值εcr後之值之領域。亦即，領域A與B之ε1之上限值係隨材料之σT而改變。圖12中，以2條線顯示於σT=390MPa與1200MPa之值時設定εcr=0.023後之ε1之值作為代表。σT 390~1200MPa之鋼板之ε1之值可推論大致在上述2條線之間。因此，領域A及領域B中，可成形半成品及最終成形品而不致發生皺褶。另，領域C及領域D之ε1則超過0.023，故即便成形亦將於半成品及最終成形品發生皺褶。 In Fig. 12, the range of ε 1 and the upper and lower of the curve 1 can be distinguished as the field A to the field D. Fields A and B are fields in which εcr is in the range of 0 to 0.023, that is, the field ε 1 is a field in which the value of the strain εcr is added to 0.5σ T /E. That is, the upper limit of ε 1 of the fields A and B varies with the σ T of the material. In Fig. 12, the value of ε 1 after εcr = 0.023 is set as a representative when the values of σ T = 390 MPa and 1200 MPa are shown by two lines. σ T The value of ε 1 of a steel plate of 390 to 1200 MPa can be inferred to be roughly between the above two lines. Therefore, in the fields A and B, the semi-finished product and the final molded article can be formed without wrinkles. In addition, the ε 1 of the field C and the field D exceeds 0.023, so that even if it is formed, the semi-finished product and the final molded article may wrinkle.
在此，為避免皺褶之發生而製得翹曲及扭曲較少之最終成形品，必須在ε1為εcr之領域A及領域B中，使α1-α2所定義之追加彎曲角β在預定範圍內。以下，即就追加彎曲角β之範圍區分領域A與領域B而加以說明。另，α1及α2一如圖13(a)所示，係以水平線H之位置為起點，並以凸緣部4a朝遠離頂板部2之方向旋轉之方向為正向。反之，則以水平線H之位置為起點，並以凸緣部4a朝接近頂板部2之方向旋轉之方向為正向。 Here, in order to avoid the occurrence of wrinkles and to obtain a final molded article having less warpage and distortion, it is necessary to add an additional bending angle β defined by α 1 -α 2 in the fields A and B in which ε 1 is εcr. Within the predetermined range. Hereinafter, the field A and the field B will be described by adding the range of the bending angle β. Further, as shown in Fig. 13(a), α 1 and α 2 start from the position of the horizontal line H, and the direction in which the flange portion 4a rotates away from the top plate portion 2 is the forward direction. On the other hand, the position of the horizontal line H is taken as the starting point, and the direction in which the flange portion 4a rotates in the direction close to the top plate portion 2 is the forward direction.
圖12之領域A中，α1>0、α2≧0、α1-α2>0及R0為50~2000mm時，作為α1-α2之追加彎曲角β，在【數5】中，必須在下述範圍內。 In the field A of Fig. 12, when α 1 >0, α 2 ≧0, α 1 -α 2 >0, and R 0 are 50 to 2000 mm, the additional bending angle β as α 1 -α 2 is in [5] In, must be within the following range.
在此，如圖12所示，一旦R0增大或ε1增大，【數6】之值將為負值。 Here, as shown in FIG. 12, once R 0 increases or ε 1 increases, the value of [Number 6] will be a negative value.
自該值算出反餘弦之值則如上述而為α1，故該值為負 將使α1之值超過90°。α1之值一旦超過90°，則如圖14所示，凸緣部4a與縱壁部3a形成之角度將為180°以下，圖4之模具將無法進行脫模，而無法製造成形品。故而，領域A之必要條件係須使【數7】為正值。 The value of the inverse cosine calculated from this value is α 1 as described above, so a negative value will cause the value of α 1 to exceed 90°. When the value of α 1 exceeds 90°, as shown in Fig. 14, the angle formed by the flange portion 4a and the vertical wall portion 3a is 180° or less, and the mold of Fig. 4 cannot be released from the mold, and the molded article cannot be produced. Therefore, the necessary condition of the field A is to make [7] a positive value.
上述條件下，即可求出作為自α1減去α2之值之β之值。β之上限值則可求出為0.023而為不致發生皺褶之上限之εcr之值。又，理論上，εcr亦可為零，此時，則使ε1之值為0.5σT/E。故而，β之範圍將在ε1為σT/E至0.5σT/E+εcr之範圍內所算出之值之範圍內變化。 Under the above conditions, the value of β which is a value obtained by subtracting α 2 from α 1 can be obtained. The upper limit of β can be found to be 0.023 and is the value of εcr which does not cause the upper limit of wrinkles. Further, in theory, εcr can also be zero, and in this case, the value of ε 1 is 0.5 σ T /E. Therefore, in the range of ε 1 β is σ T / E to 0.5σ T / E within the range of values within the range of the calculated variation of εcr +.
本發明之加工方法係先略微進行彎曲加工後，進而朝同方向加以彎曲之成形方法，故不致發生α1≦0之情形。又，初始即大幅加以彎曲將易發生皺褶故較不適用。且，α2<0將使凸緣部變形而於凸緣部發生皺褶而較不適用。其次，若α1-α2≦0，因本發明係在先略微進行彎曲加工後進而朝同方向加以彎曲之成形方法，故不致發生α1-α2≦0之情形。又，α1-α2≦0時將朝反方向進行加工，而易於第1成形加工時發生皺褶故較不適用。故而，設為α1>0、α2≧0、α1-α2>0。 The processing method of the present invention is a molding method in which the bending process is slightly performed and then bent in the same direction, so that α 1 ≦ 0 does not occur. Moreover, the initial bending, which is greatly bent, tends to cause wrinkles, which is less suitable. Further, α 2 <0 deforms the flange portion and wrinkles the flange portion, which is less suitable. Next, when α 1 - α 2 ≦ 0, the present invention is a molding method in which the bending process is slightly performed and then bent in the same direction, so that α 1 - α 2 ≦ 0 does not occur. Further, when α 1 -α 2 ≦0, the processing is performed in the reverse direction, and wrinkles are liable to occur during the first forming process, which is less suitable. Therefore, it is assumed that α 1 >0, α 2 ≧0, and α 1 -α 2 >0.
又，R0若未滿50mm，則第1成形步驟結束時，殘留於彎曲部10內側之縱壁部3a及凸緣部4a中之拉伸應力將大幅增加。故而，即便使β在上述不等式之範圍內，亦無法 於第2成形步驟中開放上述拉伸應力之殘留。其結果，最終成形品1之翹曲及扭曲將增加。另，R0若超過2000mm，最終成形品1之形狀將朝長向形成直線，故第1成形步驟結束時，殘留於彎曲部10內側之縱壁部3a及凸緣部4a中之拉伸應力將減少。故而，即便不應用本發明，最終成形品1之翹曲及扭曲亦將減少。進而，最終成形品具有複數種曲率時，本發明則將最小之曲率半徑設為R0。 Further, when R 0 is less than 50 mm, the tensile stress remaining in the vertical wall portion 3a and the flange portion 4a inside the curved portion 10 at the end of the first molding step is greatly increased. Therefore, even if β is within the range of the above inequality, the above-mentioned tensile stress cannot be left in the second molding step. As a result, warpage and distortion of the final molded article 1 will increase. On the other hand, when R 0 exceeds 2000 mm, the shape of the final molded product 1 is linearly formed in the longitudinal direction, so that the tensile stress remaining in the vertical wall portion 3a and the flange portion 4a inside the curved portion 10 at the end of the first molding step Will be reduced. Therefore, even if the present invention is not applied, the warpage and distortion of the final molded article 1 will be reduced. Further, in the case where the final molded article has a plurality of kinds of curvatures, the present invention sets the minimum radius of curvature to R 0 .
又，【數8】中，作為α2+β之α1係以前述水平線為起點而超過90°。圖14係顯示作為α2+β之α1超過90°時之圖1(a)中之I-I線之最終成形品之截面者。如圖14所示，凸緣部4a對模具之行進方向形成逆梯度，而明顯無法使用模具成形最終成形品1。 Further, in [Equation 8], α 1 as α 2 +β is more than 90° from the horizontal line as a starting point. Fig. 14 is a view showing a cross section of the final molded product of the line II in Fig. 1(a) when α 1 of α 2 + β exceeds 90°. As shown in Fig. 14, the flange portion 4a forms an inverse gradient to the traveling direction of the mold, and it is apparent that the final molded article 1 cannot be formed using a mold.
其次，追加彎曲角β之範圍若未滿足【數9】，則可成形半成品及最終成形品1而不致發生皺褶，但最終成形品1之翹曲及扭曲將增加。 Next, if the range of the additional bending angle β is not satisfied [9], the semi-finished product and the final molded product 1 can be formed without wrinkles, but the warpage and distortion of the final molded article 1 will increase.
接著，圖12之領域B中，若α1>0、α2≧0、α1-α2>0、 及R0為50~2000mm，作為α1-α2之追加彎曲角β，在【數10】中，必須在下述範圍內。 Next, in the field B of Fig. 12, if α 1 >0, α 2 ≧0, α 1 -α 2 >0, and R 0 are 50 to 2000 mm, as the additional bending angle β of α 1 -α 2 , In the number 10], it must be within the following range.
設定α1>0、α2≧0、α1-α2>0及R0為50~2000mm之理由則與領域A之情形相同。 The reason why α 1 >0, α 2 ≧0, α 1 -α 2 >0, and R 0 of 50 to 2000 mm is set is the same as in the case of the field A.
又，若未滿足【數11】，則如上所述，作為α2+β之α1將以前述水平線為起點而超過90°，凸緣部4a將對模具之行進方向形成逆梯度，而無法使用模具進行成形。因此，將追加彎曲角β之上限設為90°-α2。在此，則設定α1=90°。 Further, if [Number 11] is not satisfied, as described above, α 1 as α 2 + β will exceed 90° from the horizontal line as described above, and the flange portion 4a will form an inverse gradient to the traveling direction of the mold, and cannot Forming using a mold. Therefore, the upper limit of the additional bending angle β is set to 90°−α 2 . Here, α 1 =90° is set.
將追加彎曲角β設在以上所說明之範圍內，即可製得不於凸緣部4a發生皺褶且翹曲及扭曲均減少之最終成形品1。 By setting the additional bending angle β within the range described above, the final molded article 1 which is not wrinkled by the flange portion 4a and which has reduced warpage and distortion can be obtained.
最終成形品1若為圖1~圖3及圖7~圖11所示之形狀，則可應用本發明。圖1~圖3及圖7~圖11所示之形狀之最終成形品1係諸如汽車用之前縱樑、前柱內板、車頂縱梁內板等 The present invention can be applied to the final molded article 1 in the shape shown in Figs. 1 to 3 and Figs. 7 to 11 . The final molded product 1 of the shape shown in Figs. 1 to 3 and Figs. 7 to 11 is such as a front longitudinal beam for an automobile, an inner panel of a front pillar, an inner panel of a roof rail, and the like.
彎曲部10於交集部5a、5b具有圓弧形狀、楕圓圓弧形狀或連續改變曲率之曲線形狀，但上述曲線之曲率半徑若為50~2000mm，則曲線形狀並無限制。 The curved portion 10 has a circular arc shape, a circular arc shape, or a curved shape in which the curvature is continuously changed in the intersection portions 5a and 5b. However, if the curvature radius of the curved line is 50 to 2000 mm, the curved shape is not limited.
又，亦可不於最終成形品1中設有1個彎曲部10，而設有複數個。第3圖即顯示包含頂板部、縱壁部及凸緣部並於長向上設有2個曲率半徑為800mm與1200mm之彎曲部之帽型截面形狀之最終成形品之一例者。 Further, a plurality of curved portions 10 may be provided in the final molded article 1, and a plurality of them may be provided. Fig. 3 is a view showing an example of a final molded article including a top plate portion, a vertical wall portion, and a flange portion, and having a hat-shaped cross-sectional shape having two curved portions having a curvature radius of 800 mm and 1200 mm in the longitudinal direction.
第3圖之最終成形品1包含彎曲部10-1、10-2，該等彎曲部10-1、10-2之內側之凸緣部4-1a、4-2a將分別在上述β之範圍內進行追加彎曲。 The final molded product 1 of Fig. 3 includes curved portions 10-1 and 10-2, and the flange portions 4-1a and 4-2a on the inner sides of the curved portions 10-1 and 10-2 are respectively in the range of β described above. Additional bending is performed inside.
第3圖之最終成形品1中亦於第1成形步驟結束時殘留於彎曲部10、10-1、10-2之內側之縱壁部3a、3-1a、3-2a及凸緣部4a、4-1a、4-2a中之拉伸應力可藉第2成形步驟而減少。其結果，第3圖之最終成形品1亦減少了翹曲及扭曲，且，凸緣部4a、4-1a、4-2a並未發生皺褶。 In the final molded product 1 of Fig. 3, the vertical wall portions 3a, 3-1a, 3-2a and the flange portion 4a remaining inside the curved portions 10, 10-1, and 10-2 at the end of the first molding step are also present. The tensile stress in 4-1a, 4-2a can be reduced by the second forming step. As a result, the final molded article 1 of Fig. 3 also has reduced warpage and distortion, and the flange portions 4a, 4-1a, and 4-2a are not wrinkled.
圖1之最終成形品1中，頂板部2a之寬度W並無特別之限制。然而，寬度W為15~30mm而較窄時，則宜採用以下說明之方法進行壓製成形。另，寬度W意指第1圖之最終成形品1之頂板部2之與長向成直角之方向之寬度。 In the final molded article 1 of Fig. 1, the width W of the top plate portion 2a is not particularly limited. However, when the width W is 15 to 30 mm and is narrow, it is preferable to carry out press forming by the method described below. Further, the width W means the width of the top plate portion 2 of the final molded product 1 of Fig. 1 in a direction at right angles to the longitudinal direction.
第4圖係顯示第1圖之最終成形品1之壓製成形所 使用之模具中，使用於第1成形步驟之模具中用於成形彎曲部10之部分之截面構造之概況之模式圖。第5圖係顯示寬度W為15~30mm之第1圖之最終成形品1之壓製成形所使用之模具中，使用於第1成形步驟之模具中用於成形彎曲部10之部分之截面構造之概況之模式圖。第6圖係顯示寬度W為15~30mm之第1圖之最終成形品1之壓製成形所使用之模具中，使用於第2成形步驟之模具中用於成形彎曲部10之部分之截面構造之概況之模式圖。 Fig. 4 is a view showing a press forming station of the final molded product 1 of Fig. 1. In the mold used, a schematic view of an outline of a cross-sectional structure of a portion for forming the curved portion 10 in the mold of the first forming step is used. Fig. 5 is a cross-sectional view showing a portion of the mold for forming the curved portion 10 in the mold used in the first molding step in the mold used for press molding of the final molded product 1 in Fig. 1 having a width W of 15 to 30 mm. Schematic diagram of the overview. Fig. 6 is a cross-sectional view showing a portion of a mold used for press forming in the second forming step in the mold used for press forming of the final molded product 1 in the first drawing having a width W of 15 to 30 mm. Schematic diagram of the overview.
如第4圖所示，第1模具50及第2模具60包含頂板部成形面52、62、內側縱壁部成形面53a、63a、外側縱壁部成形面53b、63b、內側凸緣部成形面54a、64a、外側凸緣部成形面54b、64b。 As shown in Fig. 4, the first mold 50 and the second mold 60 include top plate forming surfaces 52 and 62, inner vertical wall forming surfaces 53a and 63a, outer vertical wall forming surfaces 53b and 63b, and inner flange forming portions. Surfaces 54a and 64a and outer flange forming surfaces 54b and 64b.
第1成形步驟中，鋼板90為第1模具50及第2模具60所夾持時，於最終成形品1中構成頂板部2之部位92將自第2模具60之頂板部成形面62上抬。其次，部位92將朝鋼板90之板厚方向大幅彎曲。此時，最終成形品1中構成頂板部2之部位92上，力矩將朝鋼板90之板厚方向作用，而於頂板部2殘留可彎曲最終成形品1整體之應力(以下稱為彎曲應力)。該彎曲應力之殘留則將導致藉第2成形步驟減少第1成形步驟結束時所殘留之拉伸應力之效果之降低。為抑制彎曲應力之殘留，而須增大成形壓力。然而，最終成形品1之寬度W為15~30mm而較窄時，尤其需要較大之成形壓力。 In the first molding step, when the steel sheet 90 is sandwiched between the first mold 50 and the second mold 60, the portion 92 constituting the top plate portion 2 in the final molded product 1 is lifted from the top plate forming surface 62 of the second mold 60. . Next, the portion 92 will be greatly bent toward the thickness direction of the steel sheet 90. At this time, in the portion 92 of the final molded product 1 constituting the top plate portion 2, the moment acts on the plate thickness direction of the steel plate 90, and the stress on the entire final molded article 1 (hereinafter referred to as bending stress) remains in the top plate portion 2. . The residual of the bending stress causes a decrease in the effect of reducing the tensile stress remaining at the end of the first forming step by the second forming step. In order to suppress the residual of the bending stress, the forming pressure must be increased. However, when the width W of the final molded article 1 is 15 to 30 mm and is narrow, a large molding pressure is particularly required.
因此，寬度W為15~30mm而較窄時，則使第4圖之第1模具50如第5圖所示而分割成襯墊55b、局部成形模具 56a。藉此，即可以襯墊55b與第2模具60夾持最終成形品1中構成外側縱壁部3b及外側凸緣部4b之部分，同時藉局部成形模具56a成形內側縱壁部3a及內側凸緣部4a。即，可藉襯墊55b與第2模具60壓緊鋼板90，而藉局部成形模具56a與第2模具60使鋼板90塑性變形而成形內側縱壁部3a及內側凸緣部4a。如此，即可避免彎曲應力殘留於頂板部2，而無須增加成形壓力。另，可藉安裝於壓製機80之小型油壓汽缸81朝第2模具60壓附襯墊55b。此係因僅以襯墊55b及第2模具60夾持鋼板90，故無須施加較大負載之故。 Therefore, when the width W is 15 to 30 mm and is narrow, the first mold 50 of Fig. 4 is divided into a spacer 55b and a partial forming mold as shown in Fig. 5. 56a. With this configuration, the spacer 55b and the second mold 60 sandwich the portion of the final molded product 1 that constitutes the outer vertical wall portion 3b and the outer flange portion 4b, and the inner vertical wall portion 3a and the inner convex portion are formed by the partial molding die 56a. Edge 4a. In other words, the steel sheet 90 can be pressed against the second mold 60 by the spacer 55b, and the steel sheet 90 can be plastically deformed by the partial molding die 56a and the second mold 60 to form the inner vertical wall portion 3a and the inner flange portion 4a. Thus, it is possible to prevent the bending stress from remaining on the top plate portion 2 without increasing the forming pressure. Further, the spacer 55b can be pressed toward the second mold 60 by the small hydraulic cylinder 81 attached to the press machine 80. Since the steel sheet 90 is sandwiched only by the spacer 55b and the second mold 60, it is not necessary to apply a large load.
其次，一如第6圖所示，就第2成形步驟所使用之模具使用第2模具60、襯墊55a及局部成形模具56b，即可以襯墊55a及第2模具60夾持頂板部2及內側縱壁部3a，同時藉襯墊55a就內側凸緣部4a進行追加彎曲加工，並藉局部成形模具56b與第2模具60成形外側縱壁部3b及外側凸緣部4b。即，可藉襯墊55a與第2模具60壓緊第1成形步驟中製得之成形半成品，同時藉襯墊55a與第2模具60使內側凸緣部4a塑性變形而進行追加彎曲加工，並藉局部成形模具56b與第2模具60而使鋼板90塑性變形以成形外側縱壁部3b及外側凸緣部4b。藉此，而可不於頂板部2殘留彎曲應力。另，可藉安裝於壓製機80之小型油壓汽缸81壓附襯墊55a。此乃因內側凸緣部4a之追加彎曲無須施加較大負載之故。 Next, as shown in Fig. 6, the second mold 60, the spacer 55a, and the partial molding die 56b are used for the mold used in the second molding step, that is, the top plate portion 2 can be sandwiched between the spacer 55a and the second mold 60. The inner vertical wall portion 3a is additionally bent by the inner peripheral flange portion 4a by the spacer 55a, and the outer vertical wall portion 3b and the outer flange portion 4b are formed by the partial molding die 56b and the second die 60. In other words, the forming mold semi-finished product obtained in the first molding step can be pressed by the spacer 55a and the second mold 60, and the inner flange portion 4a can be plastically deformed by the spacer 55a and the second mold 60 to perform additional bending processing. The steel sheet 90 is plastically deformed by the partial molding die 56b and the second die 60 to form the outer vertical wall portion 3b and the outer flange portion 4b. Thereby, the bending stress does not remain in the top plate portion 2. Further, the gasket 55a can be pressed by the small hydraulic cylinder 81 attached to the press machine 80. This is because the additional bending of the inner flange portion 4a does not require a large load.
如以上之說明，第1成形步驟中，以襯墊55a與第2模具60夾持頂板部2及內側縱壁部3a，同時藉局部成形模具56a成形頂板部2與內側縱壁部3a及內側凸緣部4a。其 次，第2成形步驟中，則藉襯墊55a進行第1成形步驟後之內側凸緣部4a之追加彎曲加工，並藉局部成形模具56b成形外側縱壁部3b及外側凸緣部4b。 As described above, in the first molding step, the top plate portion 2 and the inner vertical wall portion 3a are sandwiched by the spacer 55a and the second mold 60, and the top plate portion 2 and the inner vertical wall portion 3a and the inner side are formed by the partial molding die 56a. Flange portion 4a. its In the second molding step, the inner flange portion 4a after the first molding step is additionally bent by the spacer 55a, and the outer vertical wall portion 3b and the outer flange portion 4b are formed by the partial molding die 56b.
如上而進行成形，即可更為提昇就內側凸緣部4a進行追加彎曲所致最終成形品1之翹曲及扭曲之減少之效果。尤其，在W為15~30mm時較為有效。 When the molding is carried out as described above, the effect of reducing the warpage and distortion of the final molded article 1 by additionally bending the inner flange portion 4a can be further enhanced. In particular, it is effective when W is 15 to 30 mm.
以下，將藉實施例進而說明本發明，但實施例中之條件乃為確認本發明之可實施性及效果而採用之一條件例，本發明並不受限於該一條件例。本發明在不逸脫本發明要旨而可達成本發明之目的之限度內，可採用各種條件。 Hereinafter, the present invention will be further described by way of examples, but the conditions in the examples are examples of conditions for confirming the practicability and effects of the present invention, and the present invention is not limited to the examples. The present invention can adopt various conditions within the limits of the purpose of the invention without departing from the gist of the invention.
已使用各種板厚、拉伸強度之鋼板，並藉本發明之方法進行壓製成形，而製成圖1、圖3及圖11a~圖11i所示之最終成形品1。 Steel sheets of various thicknesses and tensile strengths have been used, and press forming has been carried out by the method of the present invention to produce the final molded article 1 shown in Figs. 1, 3 and 11a to 11i.
已就製成之最終成形品1全體進行翹曲及扭曲之評價如下。並已就各最終成形品1實測了圖1、圖3所示之4點P0、Q0、S0、T0之位置，並將其等之座標設為點P、Q、S、T。其次，將P0=P、Q0=Q、S0=S之3點固定後之線段T0T設為翹曲及扭曲量。即，完全未翹曲及扭曲時，將為P0=P、Q0=Q、S0=S及T0=T，故線段T0T所代表之翹曲及扭曲量為0。另，圖11a~圖11i中之4點P0、Q0、S0、T0則以圖1及圖3為準。 The evaluation of warpage and distortion of the entire final molded article 1 has been made as follows. The positions of the four points P 0 , Q 0 , S 0 , and T 0 shown in Fig. 1 and Fig. 3 have been measured for each final molded product 1, and the coordinates thereof are set as points P, Q, S, and T. . Next, the line segment T 0 T at which the three points of P 0 = P, Q 0 = Q, and S 0 = S are fixed is set as the amount of warpage and distortion. That is, when it is completely unwarped and twisted, it will be P 0 = P, Q 0 = Q, S 0 = S, and T 0 = T, so the amount of warpage and distortion represented by the line segment T 0 T is zero. In addition, the four points P 0 , Q 0 , S 0 , and T 0 in FIGS. 11 a to 11 i are based on FIGS. 1 and 3 .
評價結果顯示於表1。表1中，亦已列舉最終成形品1相當於圖1、圖3及圖11a~圖11i之何者、寬度W之值、使 用之鋼板之板厚、拉伸強度及追加彎曲角β、襯墊55a、55b之使用有無等。 The evaluation results are shown in Table 1. In Table 1, the final molded article 1 corresponds to the values of the width W of Figs. 1, 3, and 11a to 11i, and The thickness of the steel sheet used, the tensile strength, the additional bending angle β, the presence or absence of the use of the spacers 55a and 55b, and the like.
由表1可知，已確認將追加彎曲角β設在本發明之範圍內，則即便將440~1600MPa之高強度鋼板成形為圖1、圖3及圖11a~圖11i所示之最終成形品1後，翹曲及扭曲量亦將與成形拉伸強度為390MPa之軟鋼板後相同，內側凸緣部4a、4-1a、4-2a亦未發生皺褶。另，已確認對翹曲及扭曲量造成影響之因子中，追加彎曲角β之影響極大。並已確認本發明之β之範圍內，可將翹曲及扭曲量抑制在17mm以下。又，亦已確認與非如本發明般分2階段進行成形而藉單次成形製得最終成形品1之習知例相較，發明例之翹曲及扭曲量已大幅減少。 As can be seen from Table 1, it has been confirmed that the additional bending angle β is within the range of the present invention, and even a high-strength steel sheet of 440 to 1600 MPa is formed into the final molded product 1 shown in Figs. 1, 3, and 11a to 11i. Thereafter, the amount of warpage and twisting was also the same as that of the soft steel sheet having a tensile strength of 390 MPa, and the inner flange portions 4a, 4-1a, and 4-2a were not wrinkled. In addition, among the factors that affect the amount of warpage and distortion, the influence of the additional bending angle β is extremely large. It has been confirmed that the amount of warping and twisting can be suppressed to 17 mm or less within the range of β of the present invention. Further, it has been confirmed that the warpage and the amount of warpage of the invention examples are greatly reduced as compared with the conventional example in which the final molded article 1 is produced by a single molding in two stages instead of the present invention.
尤其，亦一併確認了當W為15~30mm時，使用襯墊55a、55b之效果較佳。 In particular, it has also been confirmed that when W is 15 to 30 mm, the effects of using the spacers 55a and 55b are preferable.
另，已確認追加彎曲角β在本發明之下限之外時，翹曲及扭曲量大於成形440MPa之軟鋼板時。 Further, it has been confirmed that when the additional bending angle β is outside the lower limit of the present invention, the amount of warping and twisting is larger than when forming a soft steel sheet of 440 MPa.
且，已確認追加彎曲角β在本發明之上限之外時，翹曲及扭曲量與成形440MPa之軟鋼板後相同，但內側凸緣部4a、4-1a、4-1b發生了皺褶。 Further, when it is confirmed that the additional bending angle β is outside the upper limit of the present invention, the amount of warping and twisting is the same as that after forming the soft steel sheet of 440 MPa, but the inner flange portions 4a, 4-1a, and 4-1b are wrinkled.
第7圖係顯示汽車車體之骨架結構之車頂外板加強件者。該零件一如第7圖所示，具有朝長向和緩彎曲之形狀(在最小半徑700mm~最大半徑1200mm之範圍內連續改變曲率之形狀)。 Fig. 7 is a figure showing the roof outer panel reinforcement of the skeleton structure of the automobile body. As shown in Fig. 7, the part has a shape that is elongated and gently curved (a shape in which the curvature is continuously changed in a range from a minimum radius of 700 mm to a maximum radius of 1200 mm).
一旦壓製成形上述朝長向彎曲之車頂外板加強件，則在成形縱壁部3a時，將因頂板面上發生之板厚方向 之力矩與形成內側凸緣部4a時所發生之拉伸應力，而發生翹曲及扭曲。 Once the above-mentioned long-side curved roof outer panel reinforcement is press-formed, when the vertical wall portion 3a is formed, the thickness direction of the roof surface is generated. The moment and the tensile stress occurring when the inner flange portion 4a is formed are warped and twisted.
因此，使用板厚1.0mm、拉伸強度980MPa之高強度鋼板而實施了前述第1成形步驟與第2成形步驟。實驗水準2-1係未如本發明般分2階段進行成形而藉單次成形製得最終成形品1之習知例。實驗水準2-2則為已實施本發明之第1成形步驟與第2成形步驟之發明例。先端部之回彈之測定結果(翹曲及扭曲量)顯示於表2。另，翹曲及扭曲量係藉以第1實施例為依據之方法而進行評價。 Therefore, the first forming step and the second forming step were carried out using a high-strength steel sheet having a thickness of 1.0 mm and a tensile strength of 980 MPa. The experimental level 2-1 is a conventional example in which the final molded article 1 is produced by a single molding without being formed in two stages as in the present invention. The experimental level 2-2 is an inventive example in which the first forming step and the second forming step of the present invention have been carried out. The measurement results of the rebound of the tip end (warpage and twist amount) are shown in Table 2. Further, the amount of warping and twisting was evaluated by the method based on the first embodiment.
實驗水準3-1之習知例大幅發生了翹曲及扭曲。相對於此，實驗水準2-2之發明例則確認了藉實施第1成形步驟與第2成形步驟而可抑制翹曲及扭曲。 The conventional example of the experimental level 3-1 has undergone significant warpage and distortion. On the other hand, in the inventive example of the experimental level 2-2, it was confirmed that warpage and distortion can be suppressed by performing the first molding step and the second molding step.
實際之零件中，一如前述第8圖所示而存在有凹口。且，存在有採用焊接或螺接等之組裝時所使用之接合座面或焊道形狀等。此係為避免在朝長向彎曲之部位上於組裝時與對象零件發生干擾之故。或者，目的在提昇強度等。 In the actual part, there is a notch as shown in the above-mentioned Fig. 8. Further, there is a joint seating surface or a bead shape used for assembly by welding or screwing or the like. This is to avoid interference with the target part at the time of assembly toward the long curved portion. Or, the purpose is to increase the strength and the like.
一旦壓製成形朝長向彎曲之零件，則在成形縱壁部3a時，將因頂板面上發生之鋼板之板厚方向之力矩與成形內側凸緣部4a時所發生之拉伸應力，而發生翹曲及扭曲。 When the part bent toward the long direction is press-formed, when the vertical wall portion 3a is formed, the moment in the thickness direction of the steel sheet which occurs on the top surface and the tensile stress which occurs when the inner flange portion 4a is formed occur. Warping and twisting.
因此，對板厚1.0mm、拉伸強度980MPa之高強度鋼板實施了前述第1成形步驟與第2成形步驟。實驗水準3-1係未如本發明般分2階段進行成形而藉單次成形製得最終成形品1之習知例。實驗水準3-2則為已對第8圖之虛線所示之範圍之內側凸緣部實施本發明之第1成形步驟與第2成形步驟之發明例。最終成形品1之翹曲及扭曲量之測定結果顯示於表3。另，翹曲及扭曲量係藉以第1實施例為依據之方法而進行評價。 Therefore, the first forming step and the second forming step were performed on a high-strength steel sheet having a thickness of 1.0 mm and a tensile strength of 980 MPa. The experimental level 3-1 is a conventional example in which the final molded article 1 is produced by a single molding without being formed in two stages as in the present invention. The experimental level 3-2 is an invention example in which the first forming step and the second forming step of the present invention are carried out on the inner flange portion of the range indicated by the broken line in Fig. 8. The measurement results of the warpage and the amount of distortion of the final molded article 1 are shown in Table 3. Further, the amount of warping and twisting was evaluated by the method based on the first embodiment.
實驗水準3-1之習知例已大幅發生翹曲及扭曲。相對於此，實驗水準3-2之發明例則已確認藉實施第1成形步驟與第2成形步驟而可抑制翹曲及扭曲。 The conventional example of the experimental level 3-1 has been greatly warped and distorted. On the other hand, in the inventive example of the experimental level 3-2, it was confirmed that warpage and distortion can be suppressed by performing the first forming step and the second forming step.
於內側凸緣實施追加彎曲加工之範圍亦可為局部。因此，實驗水準4-2之發明例係已對第9圖中以虛線代表之範圍之內側凸緣部實施本發明之第1成形步驟與第2成形步驟者。最終成形品1之翹曲及扭曲量之測定結果顯示於表4。另，翹曲及扭曲量係藉以第1實施例為依據之方法而進行評價。且，並準備未如本發明般分2階段進行成形而藉單次成形製得最終成形品1之習知例作為實驗水準4-1，而一併進行評價。 The range in which the additional bending process is performed on the inner flange may be partial. Therefore, in the invention example of the experimental level 4-2, the first forming step and the second forming step of the present invention were carried out on the inner flange portion of the range indicated by the broken line in Fig. 9. The measurement results of the warpage and the amount of distortion of the final molded article 1 are shown in Table 4. Further, the amount of warping and twisting was evaluated by the method based on the first embodiment. Further, a conventional example in which the final molded product 1 was produced by a single molding without being formed in two stages as in the present invention was prepared as the experimental level 4-1, and was evaluated together.
實驗水準4-2之發明例已確認因實施第1成形步驟與第2成形步驟而抑制了翹曲及扭曲。相對於此，實驗水準4-1之習知例則大幅發生了翹曲及扭曲。 In the invention example of the experimental level 4-2, it was confirmed that warpage and distortion were suppressed by performing the first molding step and the second molding step. In contrast, the conventional example of the experimental level 4-1 has greatly warped and twisted.
第10圖係顯示汽車車體之骨架結構之車頂外板加強件之局部者。一旦壓製成形上述朝長向彎曲之車頂外板加強件，則在成形縱壁部時，將因頂板面上發生之鋼板之板厚之力矩與形成內側凸緣部時所發生之拉伸應力，而發生翹曲及扭曲。 Fig. 10 is a view showing a part of the roof outer panel reinforcing member of the skeleton structure of the automobile body. Once the above-mentioned long-curved roof outer panel reinforcement is press-formed, the moment of the thickness of the steel sheet occurring on the top surface and the tensile stress occurring when the inner flange portion is formed are formed when the vertical wall portion is formed And warp and distortion occur.
因此，對板厚1.0mm、拉伸強度980MPa等級之高強度鋼板實施了前述第1成形步驟與第2成形步驟。實驗水準6係未如本發明般分2階段進行成形而藉單次成形製得最終成形品1之習知例。實驗水準7則為已實施本發明之第1成形步驟與第2成形步驟之發明例。翹曲及扭曲量之測定結果顯示於表5。另，翹曲及扭曲量係藉以第1實施例為依據之方法而進行評價。 Therefore, the first forming step and the second forming step were performed on a high-strength steel sheet having a thickness of 1.0 mm and a tensile strength of 980 MPa. The experimental level 6 is a conventional example in which the final molded article 1 is produced by a single molding without being formed in two stages as in the present invention. The experimental level 7 is an inventive example in which the first forming step and the second forming step of the present invention have been carried out. The results of the measurement of the warpage and the amount of twist are shown in Table 5. Further, the amount of warping and twisting was evaluated by the method based on the first embodiment.
實驗水準6之習知例大幅發生了翹曲及扭曲。相對於此，實驗水準7之發明例則已確認藉實施第1成形步驟與第2成形步驟而可抑制翹曲及扭曲。 The well-known examples of the experimental level 6 have been warped and distorted. On the other hand, in the inventive example of the experimental level 7, it was confirmed that warpage and distortion can be suppressed by performing the first forming step and the second forming step.
如上所述，依據本發明，即可抑制包含頂板部、縱壁部及凸緣部並於長向上設有至少1個最小曲率半徑為50~2000mm之彎曲部之最終成形品1之翹曲及扭曲。因此，可減少最終成形品之尺寸精度瑕疵。故而，本發明之產業上之利用價值極高。 As described above, according to the present invention, it is possible to suppress the warpage of the final molded article 1 including the top plate portion, the vertical wall portion, and the flange portion and having at least one bent portion having a minimum radius of curvature of 50 to 2000 mm in the long direction. distortion. Therefore, the dimensional accuracy of the final molded article can be reduced. Therefore, the industrial use value of the present invention is extremely high.
1‧‧‧最終成形品 1‧‧‧ final molded product
2‧‧‧頂板部 2‧‧‧ top board
3a、3b‧‧‧縱壁部 3a, 3b‧‧‧ vertical wall
4a、4b‧‧‧凸緣部 4a, 4b‧‧‧Flange
5a、5b‧‧‧交集部 5a, 5b‧‧‧Intersection Department
10‧‧‧彎曲部 10‧‧‧Bend
H‧‧‧水平線 H‧‧‧ horizontal line
L1‧‧‧線段 L1‧‧‧ line segment
L2、L3‧‧‧位置 L2, L3‧‧‧ position
Lo‧‧‧曲率中心軸 Lo‧‧‧ Curvature Center Axis
Lo’‧‧‧軸 Lo’‧‧‧ axis
O‧‧‧曲率中心 O‧‧‧ Curvature Center
P0、Q0、S0、T0‧‧‧最終成形品之位置測定點 P 0 , Q 0 , S 0 , T 0 ‧‧‧ Position measurement point of the final molded product
r‧‧‧位置 R‧‧‧ position
S1‧‧‧微小平面 S1‧‧‧micro plane
W‧‧‧頂板部之寬度 W‧‧‧The width of the top plate
α1、α2‧‧‧角度 α 1 , α 2 ‧‧‧ angle
β‧‧‧追加彎曲角 β‧‧‧Additional bending angle
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| Publication number | Priority date | Publication date | Assignee | Title |
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| TWI602627B (en) * | 2014-12-22 | 2017-10-21 | 新日鐵住金股份有限公司 | Hat-shaped cross-section component manufacturing method |
| TWI606874B (en) * | 2015-04-22 | 2017-12-01 | 新日鐵住金股份有限公司 | Method for producing press-molded article, press-molded article and press apparatus |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| TWI602627B (en) * | 2014-12-22 | 2017-10-21 | 新日鐵住金股份有限公司 | Hat-shaped cross-section component manufacturing method |
| TWI606874B (en) * | 2015-04-22 | 2017-12-01 | 新日鐵住金股份有限公司 | Method for producing press-molded article, press-molded article and press apparatus |
| US11014139B2 (en) | 2015-04-22 | 2021-05-25 | Nippon Steel Corporation | Pressed component manufacturing method, pressed component, and pressing apparatus |
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